Apparatus and method for deconstructing mattresses

ABSTRACT

A method and apparatus for deconstructing a mattress of the type having steel coil springs held within fabric pockets. The apparatus includes a frame and an opener mechanism mounted to the frame and operable for opening a plurality of fabric pockets at a first end thereof to create an opening in the first end of the fabric pockets and expose the steel coil springs contained therewithin. A gripper mechanism is provided for gripping the plurality of fabric pockets at a second end thereof, opposite the first end. An extractor mechanism is mounted to the frame for extracting the steel coil springs from the fabric pockets through the openings formed in the first end of the fabric pockets.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application claims the priority benefit of U.S. provisionalapplications Ser. Nos. 63/065,645, 63/065,655, and 63/065,650, all filedon Aug. 14, 2020.

TECHNICAL FIELD

The present invention relates generally to recycling and, in particular,to deconstructing certain types of mattresses for recycling same.

BACKGROUND

Mattresses have been constructed in many ways over the years. Somewithout any springs, while others have had springs extending laterallyfor helping to support users sleeping atop the mattresses. In recentyears, the so-called pocket coil spring mattress has begun to becomemore and more popular.

Pocket coils or pocketed coils (also known as Marshall Coils) are apopular construction type for inner spring mattresses because theyisolate the transfer of movement to individual coils. Mattresses withpocket coils often have between 250 and 1,000 individual spring coils.These metal coils are individually encapsulated in either polypropyleneor woven cotton fabric. The coil jackets in some constructions are boundtogether using stitching or hot melt adhesives. In some otherconstructions, the coil jackets are not connected, resting freely insidethe mattress walls.

Pocketed coils are springs wrapped individually in a fabric sleeve andare popular with consumers because the springs react to pressureindependently. This construction minimizes movement and allows for amore buoyant feel. At the end of their product life, however, pocketedcoil layers have proven difficult to recycle. MRC estimates that pocketcoil mattresses represent at least 25% of the current recycling stream.Given the popularity of this construction in recent years, thepercentage of pocketed coil mattresses is steadily increasing.

When a mattress is deconstructed, the pocketed coil layer is easilyseparated from other components, but it is impractical to manually cutthe fabric sleeves to remove the metal coils inside. Despite pocketedcoils containing over 90% metal, most metal recyclers will not acceptthem due to the fabric contamination. As a result, pocketed coil unitsare sent to a landfill unless the recycler can separate the components.Since most metal recyclers will not tolerate fabric contamination, thepocket coil units are often sent to landfills.

However, mattresses with pocketed coils are burdensome to landfillsbecause they create problems for the landfill machinery. As a result,there is a growing trend for landfills operators to reject mattresseswith pocketed coils, leading to a growing disposal/recycling problem.

Accordingly, it can be seen that needs exist for an improved method andapparatus to separate the pocket fabric from the metal coil springseffectively and economically, preferably without sacrificing the revenuepotential of each component. It is to the provision of such solutions tothese and other problems that the present invention is primarilydirected.

SUMMARY

Generally described, the present invention relates to methods andapparatuses for deconstructing mattresses of the type having steel coilsprings secured within fabric pockets in order to remove and separatethe steel coil springs from the fabric pockets.

In a first example embodiment, the invention relates to an apparatus fordeconstructing a mattress of the type having steel coil springs heldwithin fabric pockets. The apparatus includes a frame and an openermechanism mounted to the frame and operable for opening a plurality offabric pockets at a first end thereof to create an opening in the firstend of the fabric pockets and expose the steel coil springs containedtherewithin. A gripper mechanism is provided for gripping the pluralityof fabric pockets at a second end thereof, opposite the first end. Anextractor mechanism is mounted to the frame for extracting the steelcoil springs from the fabric pockets through the openings formed in thefirst end of the fabric pockets.

Preferably, the gripper mechanism includes a gang of rotatablecorkscrew-like elements and a drive for driving the rotatablecorkscrew-like elements in rotation into the second end of the fabricpockets.

Preferably, the opener mechanism is mounted to the frame forlongitudinal movement along the frame and includes a high-speed rotatingblade mounted for side to side movement across the frame to engage a rowof fabric pockets one after another.

Preferably, the apparatus also includes a gauging mechanism foradjusting the spacing of the gang of rotatable corkscrew-like elementsto adjust the gripper mechanism to match the coil spacing of aparticular mattress. Optionally, the gauging mechanism includes apantograph mechanism for adjusting the spacing of the corkscrew-likeelements while keeping the spacing consistent from one corkscrew-likeelement to the next.

Also, preferably the apparatus includes a support platform mounted tothe frame for movably supporting a mattress thereupon for processing,and the gripper mechanism is mounted above the platform and the openermechanism is mounted below the platform.

Preferably, the extractor mechanism operates to pull the steel coilsprings downwardly through the openings formed in the fabric pockets bythe opener mechanism.

Optionally, the extractor mechanism includes an elongate element forengaging the steel coil springs and wherein the elongate element ismounted for movement away from the fabric pockets to pull the steel coilsprings out of the fabric pockets as a group. In one example, theelongate element is a blade-like element.

Preferably, the apparatus is configured for indexing the position of themattress being deconstructed to present a first row of fabric pocketsand steel coil springs for processing, and after removing the steel coilsprings from the first row, indexing the position of the mattress againto present a subsequent row of fabric pockets and steel coil springs forprocessing, and continuing to process the fabric pockets and steel coilsprings and indexing the position of the mattress until there are nofurther rows of fabric pockets and steel coil springs remaining to beprocessed.

Optionally, a jam detector is mounted to the frame for detecting thepresence of a coil spring in a location likely to cause a jam. In oneexample form, the jam detector includes a swinging arm that sweepsthrough an arc to detect a steel coil spring in its path where oneshouldn't be.

Optionally, the mattress is oriented substantially horizontally duringprocessing and the extraction of the steel coil springs from the fabricpockets is carried out by pulling the steel coil springs downwardly, outof the fabric pockets.

In another example form, the invention relates to a method fordeconstructing a mattress of the type having steel coil springs heldwithin fabric pockets. It includes a step of opening a plurality offabric pockets at a first end thereof to create an opening in the firstend of the fabric pockets and expose the steel coil springs containedtherewithin. It also includes gripping the plurality of fabric pocketsat a second end thereof, opposite the first end. Also, the methodincludes extracting the steel coil springs from the fabric pocketsthrough the openings formed in the first end of the fabric pockets.

Preferably, the step of opening the plurality of fabric pocketscomprises cutting open the fabric pockets. Preferably, the step ofopening the plurality of fabric pockets comprises cutting open thefabric pockets with a high-speed rotating blade.

Optionally, the step of gripping the fabric pockets at the second endthereof is carried out after opening the fabric pockets at the first endthereof. Optionally, the step of gripping the fabric pockets at thesecond end thereof is carried out before opening the fabric pockets atthe first end thereof.

Preferably, the step of gripping the fabric pockets at the second endthereof includes rotating corkscrew-like implements into the second endof the fabric pockets.

Preferably, the step of extracting the steel coil springs comprisesengaging the steel coil springs with a movable element and moving themovable element away from the fabric pockets to pull the steel coilsprings out of the pockets.

Preferably, the method also includes the step of indexing the positionof the mattress being deconstructed to present a first row of fabricpockets and steel coil springs for processing, and after removing thesteel coil springs from the first row, indexing the position of themattress again to present a subsequent row of fabric pockets and steelcoil springs for processing, and continuing to process the fabricpockets and steel coil springs and indexing the position of the mattressuntil there are no further rows of fabric pockets and steel coil springsremaining to be processed.

Optionally, the mattress has already had an outer cover portion thereofremoved to prepare the fabric pockets and steel coil springs forprocessing. Optionally, the mattress is oriented substantiallyhorizontally during processing and the step of extracting the steel coilsprings from the fabric pockets is carried out by pulling the steel coilsprings downwardly, out of the fabric pockets.

The specific techniques and structures employed to improve over thedrawbacks of the prior devices and accomplish the advantages describedherein will become apparent from the following detailed description ofexample embodiments and the appended drawings and claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a perspective view of a mattress deconstruction apparatusaccording to a first example embodiment of the present invention.

FIG. 1B is a schematic view of the mattress deconstruction apparatus ofFIG. 1A, showing a process flow aspect thereof.

FIG. 2A is a perspective view of the mattress deconstruction apparatusof FIG. 1A, with some elements removed for illustrative purposes.

FIG. 2B is a perspective view of the mattress deconstruction apparatusof FIG. 1A, with some other elements removed for illustrative purposes.

FIG. 3 is a perspective view of the mattress deconstruction apparatus ofFIG. 1A, with still other elements removed for illustrative purposes.

FIG. 4A is a perspective view of a grip head assembly portion of themattress deconstruction apparatus of FIG. 1A.

FIG. 4B is a partially exposed, perspective view of a grip head assemblyportion of the mattress deconstruction apparatus of FIG. 1A, with someelements thereof removed for illustrative purposes.

FIG. 4C is a partially exposed, perspective view of a grip head assemblyportion of the mattress deconstruction apparatus of FIG. 1A, and showinga pantograph adjuster mechanism portion thereof.

FIG. 5 is a perspective view of a movable cutter assembly portion of themattress deconstruction apparatus of FIG. 1A.

FIG. 6 is a perspective view of a movable spring extractor assemblyportion of the mattress deconstruction apparatus of FIG. 1A.

FIG. 7A is a perspective view of the mattress deconstruction apparatusof FIG. 1A showing a jam sensor portion thereof.

FIG. 7B is an enlarged perspective view of a portion of FIG. 7A andshowing the jam sensor portion thereof.

FIG. 8 is a schematic illustration of a method of operating the mattressdeconstruction apparatus of FIG. 1A.

FIG. 9A is a perspective view of the mattress deconstruction apparatusof FIG. 1A shown from underneath with some elements removed for clarityof illustration and showing operation of a cutter mechanism portionthereof.

FIG. 9B is an enlargement of a portion of FIG. 9A.

FIG. 10A is a perspective view of the mattress deconstruction apparatusof FIG. 1A shown from underneath with some elements removed for clarityof illustration and showing operation of an extractor mechanism portionthereof in a first position.

FIG. 10B is an enlargement of a portion of FIG. 10A.

FIG. 11A is a perspective view of the mattress deconstruction apparatusof FIG. 1A shown from underneath with some elements removed for clarityof illustration and showing operation of an extractor mechanism portionthereof in a second position.

FIG. 11B is an enlargement of a portion of FIG. 11A.

DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS

Generally described, the present invention relates to a method andapparatus for deconstructing certain mattresses of the type havingpocketed coil springs. In the example embodiments shown and describedherein, a reduced scale apparatus is depicted for simplicity ofillustration. Those skilled in the art will appreciate, however, thatthe width of the machine would be significantly greater to accommodatean entire mattress. Indeed, the reduced scale example shown in thefigures depicts processing only of a certain portion of the mattressthrough the machine.

Referring now first to FIG. 1A, an apparatus 10 for deconstructing amattress is depicted. The apparatus 10 includes a frame and cabinetassembly 100, a gripper mechanism indicated generally at 200, a gaugingmechanism indicated generally at 300, a cutter mechanism 400 (notgenerally visible in FIG. 1A, but will be seen in subsequent figures),and an extractor mechanism 500. The frame and cabinet assembly 100includes a platform or worktable indicated generally at 101 upon which amattress can be supported and moved thereover. The frame and enclosure100 also includes a pair of lateral guide rails 102 and 103 which can beadjusted for width to accommodate mattresses of various widths. A humanmachine interface or HMI 110 is mounted to the frame and cabinet 100 andincludes a display and user input to allow a user to make adjustments tothe machine and control operation of machine to process mattresses.

As used herein, the term “mattress” shall be understood to encompassboth a mattress which has not been processed at all and a mattress whichhas been partially processed to prepare it for further deconstruction.Thus, “mattress” includes an intact mattress and apartially-disassembled mattress in the form of a workpiece. In thisregard, it is contemplated that many mattresses of the sort havingpocketed coils also have upper and lower coverings and outer coveringswhich would be removed prior to processing the mattress fordeconstruction with the apparatus and method of the present invention.Such upper and lower coverings and outer coverings are easily removedwith traditional methods. For example, a worker can employ a knife orscissors to remove the upper and lower coverings or the outer coveringsfor recycling.

Still referring to FIG. 1 , the frame and cabinet assembly 100 includesa perimeter frame 120 including corner stanchions 121, 122, 123, and124. Side stanchions 126 and 127 are on one side of the cabinet andframe, while another pair of side stanchions is on the other side of thecabinet and frame, but unseen in this illustration. A base 130 isconnected to and supports the upright stanchions. An upper perimeterframe 140 includes side frame rails 141 and 142, along with end rails143 and 144. Lifting hooks or eyelets are positioned at the top cornersof the corner stanchions 121-124.

The cabinet and frame assembly 100 also includes movable doors 151 and152, movable doors 153 and 154, and solid panels 156 and 157. Solidpanel 156 includes a recess or pocket 161 for connecting an air hose toan air supply coupling positioned in the pocket.

Reference is now made to FIG. 1B which illustrates, schematically, theoverall process flow when the apparatus 10 is in use. Consideration ofthe overall process flow as shown in this figure will help the reader toquickly appreciate the construction details of the example apparatusdepicted in the subsequent figures and described herein. As depicted inthis figure, a mattress M is being processed by being deconstructed intoits constituent parts. As the mattress M is moved in the direction ofdirection arrow 170, it is separated into steel coil springs and fabric,such as coil springs S and fabric F. Here, the mattress is shown asbeing supported on the platform or table 101 and moving through theapparatus 10 beneath the gripper mechanism 200 and the gauging mechanism300. The cutter mechanism 400 and the extractor mechanism 500 are notdepicted in this figure for clarity of illustration. But those elementsalso cooperate with the gripper mechanism 200 to extract the coilsprings S from the mattress M and allow the coil springs S to drop intoa receptacle 181 for collection and subsequent removal. Meanwhile, thefabric F, which had been formed into pockets containing coil springs,moves as a web of fabric into a second receptacle 182 for subsequentremoval.

Referring now to FIG. 2A, the apparatus 10 for deconstructing a mattressis depicted with certain elements removed to illustrate otherwise hiddenelements. The figure shows the apparatus 10, a gripper mechanismindicated generally at 200, the gauging mechanism indicated generally at300, the cutter mechanism 400, and the extractor mechanism 500. FIG. 2Bis a perspective view of the mattress deconstruction apparatus 10, butwith the gauging mechanism 300 removed for illustrative purposes. FIG. 3is also a perspective view of the mattress deconstruction apparatus 10,but with the gauging mechanism 300 removed for illustrative purposes.This figure shows a first location 11 where a first receptacle 181 canbe positioned for collecting separated steel coil springs and a secondlocation 12 where a second receptacle 182 can be positioned forcollecting separated fabric.

Preferably, the gripper mechanism 200 includes a gang of rotatablecorkscrew-like elements 201-206 (see FIGS. 4A-4C) and a plurality ofdrives 211-216 for driving the rotatable corkscrew-like elements 201-206in rotation into the second end of the fabric pockets. For example, asseen in FIGS. 4A-4C, six such corkscrew-like elements 201-206 are shown.Those skilled in the art will recognize that in an apparatus forprocessing an entire mattress at once (and not just the portion of themattress as shown in this example embodiment, more such corkscrew-likeelements and drives can be ganged as needed.

Preferably, the gripper mechanism 200 includes horizontal rails 221 and222 for permitting fore and aft translation along the longitudinal axis171 of the frame. Also, the gripper mechanism 200 includes verticalposts 231 and 232 for permitting up and down movement of the grippermechanism 200 relative to the frame 100. These rails and posts can takethe form of extrusions with T-tracks formed therein, for example. Thegrip mechanism 200 is the device that grips the fabric pockets of themattress during extraction of the springs and indexes the mattress tothe next row. The grip mechanism 200 consists of 6 rotary screws thatgrip the pocket at its center, holding the pocket firmly while notbinding the coil within each pocket. Each grip is free to trolley on arail until the brake pad is engaged. This allows for many spring spacingconfigurations. The current demonstrator machine has four spring spacingset points, at 2.00″, 2.25″, 2.5″, and 2.75″ spacings. Settings can beadded by adding gauges to the gauge mechanism 300.

The gripper mechanism 200 functions to grip the top of the fabric pocketand to maintain pocket shape for coil extraction. The inventor has foundthat if the shape of the pocket becomes deformed during or prior toextraction of the steel coil spring from the pocket, the steel coilspring can hang up in the fabric pocket and will resist extraction. Forthis reason, the inventor has found that it is preferred to maintain theshape of the pocket as much as possible during extraction. Further,through experimentation, the inventor has found that these rotatablecorkscrew-like elements 201-206 are particularly well suited to grippingthe fabric pockets without distorting their shape, allowing the coilsprings to be removed without getting hung up in the pockets.

Preferably, rotatable corkscrew-like elements 201-206 of the grippermechanism comprises a series of rotary rods each with an off-centersharpened point placed at the center of each coil. Preferably, the pointshould extend at least ¼″ out from the rod and approach the fabricpocket at approximately a 45 degee angle. The rotatable corkscrew-likeelements 201-206 can rotate at least 1 full revolution or somepredetermined torque. Preferably, the gripper mechanism 200 should notallow back driving (worm drive).

The gauging mechanism 300 permits one to adjust the spacing the grips tomatch the coil spacing of the mattress being deconstructed. In oneoptional form, the gauging mechanism 300 includes laser-cut gauge plates(see 301 in FIG. 2A) which are specific to particular coil diameters.The gauge plates set the grip screws to a specific coil spacing duringan automated gauging process. The gauge plates extend to the head whilethe head releases its brake and then engages the plates. The operatorselects the coil size on the HMI 110 to initiate the process. Once theprocess is complete, the grips are set for that specific mattress andcan commence processing.

However, in a more preferred form, the gauging mechanism 300 as aseparate construction is eliminated. Instead, the gauging mechanism canbe incorporated into the construction of the gripper mechanism. Indeed,as shown in FIG. 4C, the gripper mechanism can include a pantographmechanism 220 for adjusting the spacing of the various corkscrew-likeelements 201-206. The pantograph mechanism 220 is driven by an actuatorto vary the spacing in a uniform manner so that all of the spacingsbetween the various ones of the corkscrew-like elements are the same.

Preferably, the opener mechanism or cutter mechanism 400 is mounted tothe frame 100 for longitudinal back and forth movement alonglongitudinal axis 171 of the frame and includes a high-speed rotatingdisc mounted for side to side movement across the frame in direction 172to engage a row of fabric pockets one after another.

The opener mechanism 400 includes a “cutter” 401 in the form of a smoothhigh-speed circular blade-like element that opens the coil pocket,exposing the coil spring for extraction. The cutter 401 doesn't have asharp edge and so perhaps doesn't “cut” in the traditional sense ofslicing like a knife or scissors or a saw. Instead, the cutter 401 has ablunt, smooth edge and is spinning fast enough when it engages and rubsagainst the fabric of the fabric pocket, it creates an opening. It isbelieved that this is accomplished by a form of friction. Regardless ofhow the smooth cutter actually functions on a micro-scale, the neteffect is that the fabric pocket is opened without smoke, excessivedebris, or risk of fire. The cutter 401 advances longitudinally into theprepositioned row of pockets and traverses laterally across all pockets.For longitudinal movement, actuators and side rails are provided, suchas side rails 411 and 412. For the transverse lateral movements, crossrails 421 and 422 are provided (along with actuators). The cutter 401 isdriven by a high speed motor drive 402. Importantly, the cutter blade401 does not cut or become entangled with the spring.

Preferably, the cutter 401 is a smooth blade that contacts coil pocketswith a surface speed of approximately 200 ft/sec. The blade plunges intothe fabric pockets and cuts the fabric and to the extent that it makescontact with the metal coils, it does so with no damage to the coils andwithout creating sparks. In this regard, the blade material can be madeof non-sparking material, such as 304 stainless steel. The cutter orblade 401 functions flawlessly, perhaps due to the fact that it is notsharp, serrated, or non-concentric. Instead, it is a smooth laser-cutblade not requiring maintenance, sharpening, or scheduled replacement.

FIG. 9A and FIG. 9B show operation of a cutter mechanism 400 to cut openthe bottom of the fabric pockets P in the first or lead row of pockets,using the blade 401. The blade 401 is moved from one side to the otherto cut the entire row of pockets P.

The pre-compressed (preloaded) steel coil spring pushes open the capafter the cut and a flap of material acting as a hinge keeps the pocketcaps from falling off. The cutter 401 then retracts out of the way forthe extractor mechanism 500 to do its work.

Preferably, the support platform 101 is mounted to the frame 100 formovably supporting a mattress M thereupon for processing, and thegripper mechanism 200 is mounted above the platform and the openermechanism 400 is mounted below the platform.

The gauging mechanism 300 is provided for adjusting the spacing of thegang of rotatable corkscrew-like elements to adjust the grippermechanism 200 to match the coil spacing of a particular mattress.Optionally, the gripper mechanism 200 or the gauging mechanism 300includes a pantograph mechanism for adjusting the spacing of thecorkscrew-like elements while keeping the spacing consistent from onecorkscrew-like element to the next. For example, see the pantographmechanism 220 of FIG. 4C.

Preferably, the extractor mechanism 500 operates to pull the steel coilsprings downwardly through the openings formed in the fabric pockets bythe opener mechanism 400.

Optionally, the extractor mechanism 500 includes an elongate, blade-likeelement 501 for engaging the steel coil springs and wherein the elongateelement is mounted for movement away from the fabric pockets to pull thesteel coil springs out of the fabric pockets as a group. In one example,the elongate element is a blade-like element. The extractor mechanismincludes first and second rails 511, 512 for allowing the blade to beextended and retracted longitudinally along axis 513. Also, the bladecan be moved up and pulled down (as for pulling the steel coil springsdownwardly out of the fabric pockets) relative to stanchions, such asstanchion 521, by operation of air cylinders 531, 532.

FIGS. 10A-11B show operation of a retractor mechanism 500 to extract thesteel coil springs S from the opened fabric pockets P (after they havebeen cut open at the bottom of the fabric pockets P in the first or leadrow of pockets, using the blade 401). In FIGS. 10A and 10B, theretractor mechanism is shown in a raised position and with the blade 501extended into the coil springs S. Next, as shown in FIGS. 11A and 11B,the retractor mechanism is lowered to a lower position while the blade501 remains extended into the coil springs S, thus pulling the coilsprings S downwardly and out of the fabric pockets P.

Optionally, as shown in FIGS. 7A, 7B, a jam detector 600 is mounted tothe frame for detecting the presence of a coil spring in a locationlikely to cause a jam. In one example form, the jam detector 600includes a swinging arm 601 that sweeps through an arc to detect a steelcoil spring in its path where one shouldn't be. If a jammed spring goesundetected, the machine can crash and start breaking things.Off-the-shelf detector devices (optical, laser, proximity) didn't workin this application for various reasons. This jam detector 600 includesthe rod (swing arm) 601 attached to a servo motor. It simply swingsthrough the potential jam area and if it contacts a spring, the increasein torque is sensed and generates a code. This approach worked betterthan any other tried. One advantage it has is that it can swing throughfabric by brushing it aside without giving false indications and onlydetects springs where they don't belong.

The apparatus 10 includes some drive components, including 2 servomotors driving two independent rod-less ball screw actuators. Thissystem moves the grip head into position, initiates the gauging process,indexes the mattress or workpiece or sample, prepositions for cutting,and grabs the next row of fabric pockets/coil springs for processing.

Preferably, the apparatus is configured for indexing the position of themattress being deconstructed to present a first row of fabric pocketsand steel coil springs for processing, and after removing the steel coilsprings from the first row, indexing the position of the mattress againto present a subsequent row of fabric pockets and steel coil springs forprocessing, and continuing to process the fabric pockets and steel coilsprings and indexing the position of the mattress until there are nofurther rows of fabric pockets and steel coil springs remaining to beprocessed.

Optionally, the mattress is oriented substantially horizontally duringprocessing and the extraction of the steel coil springs from the fabricpockets is carried out by pulling the steel coil springs downwardly, outof the fabric pockets.

FIG. 8 is a schematic functional diagram depicting process stepsaccording to an example method of the present invention. The processshown in FIG. 8 begins with an initiation or beginning step 801. In thisinitiation step 801, the machine is initiated and adjusted to match themattress or workpiece configuration being deconstructed. For example, inthis initiation step, the operator would use the human machine interfaceor HMI 102 to input the width of the mattress and the coil spacing orcoil diameter. Next, in step 802 the workpiece or mattress is indexedinto position so that the first row of coil springs and pockets ispositioned for processing. Next, in step 803 the tops of the fabricpockets are gripped or grasped to secure them. Next or simultaneouslywith step 803, in step 804 the bottoms of the fabric pockets are opened,such as by cutting with a rotating blade. Next, in step 805, while stillgripping the pockets at the top according to step 803, the springs areextracted through the openings formed in the bottom of the fabricpockets. Next, in decision step 806 it is determine whether there areadditional rows of fabric pockets and coil springs that need to beseparated from one another. If the answer is yes, the process revertsback to step 802. If the answer is no, the process continues on to anending step 807 at which the machine is put into the rest position.

Advantageously, the methods and apparatuses of the present inventionprovide numerous benefits. For example, the method and apparatus can beimplemented to operate in a rather automated process requiring minimallabor inputs. Also, the methods and apparatuses are effective toseparate the steel coils from the fabric pockets, and direct the steelcoils to one output and to direct the fabric pockets to a differentoutput without cross contamination of either output material.Additionally, the methods and apparatuses are effective to produce cleanand separated commodities without secondary separating processes. Also,the methods and apparatuses are effective to require significantly lesspower to operate (relative to shredding processes). Further, the exampleapparatuses have a small footprint with greater potential to integrateinto existing recycling operations. Further, the methods and apparatusesare carried out and manufactured economically, which is important to theability to recycle the materials once the mattress is deconstructed.

From experiments with a demonstration apparatus according to the presentinvention, certain observations were made. These include:

-   -   Inconsistency of the mattress quality construction can cause        issues from wires poking through fabric, failed glue, joints,        tears, and debris. These inconsistencies can cause the gripping        to fail at times and that can lead to stuck coil springs. To        minimize this, the operator can conduct a quality control review        before loading the machine.    -   Coil position on the current machine is pre-set, not sensed. It        could be possible to add a sensor to detect coil position to        enhance the gripping capability and throughput and adjust to the        actual coil.    -   The first and last row of pockets/springs are most difficult to        cut and extract. The parameters of the machine could be set up        differently for the first and last rows. Grip force, compression        before cutting, and head position are examples of a few        parameters that could be tweaked for first and last rows as        compared to all other inner rows. Adding iterative testing and        evaluating results might help also.    -   The gripper mechanism and gauging process was built for six (6)        coils. A full-scale machine for whole mattresses might require a        new gripper mechanism that holds more grippers and spaces these        grippers to an appropriate spacing.    -   A continuous flow approach could be utilized. The reciprocating        methods used in the demonstrator may increase wear and cycle        times. The current process and tools could be incorporated into        a flow-type methodology, avoiding group processing which        compounds inconsistency and control problems.    -   The cutting method to open the coil pocket and expose the spring        is important. It is extremely effective, inexpensive, clean, has        low power consumption, and does not require sharpening or        replacement. This approach results in an attached hinge        requiring no post-separation of fabric from metal.    -   The grip method is extremely effective, clean, has low power        consumption, and can be easily be replaced/serviced. This is the        only method found to grip the pocket firmly without binding the        spring due to deformation of the fabric pocket.    -   Straight line, axial extraction of springs is advantageous. If        the spring is pulled axially with the coil pocket axis, minimal        effort is required to extract the spring. This allows low power        consumption and results in good reliability.    -   The quality of extracted springs and fabric are desirable and        have excellent scrap value.    -   The demonstrator has low operating costs, low consumables, low        maintenance, and low electrical requirements. This apparatus and        process is very efficient compared to grinding, shredding, and        post-process separation methods.    -   Processing coils in columns instead of rows could be done.        Turning the bed sideways could help mitigate failed glue joints        or inconsistent pocket spacing relative to gripping.

It is to be understood that this invention is not limited to thespecific devices, methods, conditions, or parameters of the exampleembodiments described and/or shown herein, and that the terminology usedherein is for the purpose of describing particular embodiments by way ofexample only. Thus, the terminology is intended to be broadly construedand is not intended to be unnecessarily limiting of the claimedinvention. For example, as used in the specification including theappended claims, the singular forms “a,” “an,” and “the” include theplural, the term “or” means “and/or,” and reference to a particularnumerical value includes at least that particular value, unless thecontext clearly dictates otherwise. In addition, any methods describedherein are not intended to be limited to the sequence of steps describedbut can be carried out in other sequences, unless expressly statedotherwise herein.

While the claimed invention has been shown and described in exampleforms, it will be apparent to those skilled in the art that manymodifications, additions, and deletions can be made therein withoutdeparting from the spirit and scope of the invention as defined by thefollowing claims.

What is claimed is:
 1. An apparatus for deconstructing a mattress of thetype having steel coil springs held within fabric pockets, the apparatuscomprising: a frame; an opener mounted to the frame and operable foropening a plurality of fabric pockets at a first end thereof to createan opening in the first end of the fabric pockets and expose the steelcoil springs contained therewithin; a gripper for gripping the pluralityof fabric pockets at a second end thereof, opposite the first end;wherein the gripper comprises a gang of rotatable corkscrew-likeelements and a drive for driving the rotatable corkscrew-like elementsin rotation into the second end of the fabric pockets; and an extractorfor extracting the steel coil springs from the fabric pockets throughthe openings formed in the first end of the fabric pockets.
 2. Theapparatus of claim 1, wherein the opener is mounted to the frame forlongitudinal movement along the frame and comprises a high-speedrotating blade mounted for side-to-side movement across the frame toengage a row of fabric pockets one after another.
 3. The apparatus ofclaim 1, wherein the extractor comprises a blade configured for engagingthe steel coil springs and wherein the blade is mounted for movementaway from the fabric pockets to pull the steel coil springs out of thefabric pockets as a group.
 4. The apparatus of claim 1, wherein theapparatus is configured for indexing the position of the mattress beingdeconstructed to present a first row of fabric pockets and steel coilsprings for processing, and after removing the steel coil springs fromthe first row, indexing the position of the mattress again to present asubsequent row of fabric pockets and steel coil springs for processing,and continuing to process the fabric pockets and steel coil springs andindexing the position of the mattress until there are no further rows offabric pockets and steel coil springs remaining to be processed.
 5. Theapparatus of claim 1, further comprising a jam detector for detectingthe presence of a coil spring in a location likely to cause a jam. 6.The apparatus of claim 1, wherein the mattress is oriented substantiallyhorizontally during processing and the step of extracting the steel coilsprings from the fabric pockets is carried out by pulling the steel coilsprings downwardly, out of the fabric pockets.
 7. The apparatus of claim1, further comprising one or more gauge plates configured for adjustinga spacing of the gang of rotatable corkscrew-like elements to adjust thegripper to match a coil spacing of a particular mattress.
 8. Theapparatus of claim 7, further comprising a pantograph for adjusting thespacing of the corkscrew-like elements while keeping the spacingconsistent from one corkscrew-like element to the next.
 9. The apparatusof claim 1, further comprising a support platform mounted to the framefor movably supporting a mattress thereupon for processing, and whereinthe gripper is mounted above the platform and the opener is mountedbelow the platform.
 10. The apparatus of claim 9, wherein the extractoroperates to pull the steel coil springs downwardly through the openingsformed in the fabric pockets by the opener.
 11. A method ofdeconstructing a mattress of the type having steel coil springs heldwithin fabric pockets utilizing the apparatus of claim 1, the methodcomprising: opening a plurality of fabric pockets at a first end thereofto create an opening in the first end of the fabric pockets and exposethe steel coil springs contained therewithin; gripping the plurality offabric pockets at a second end thereof, opposite the first end; andextracting the steel coil springs from the fabric pockets through theopenings formed in the first end of the fabric pockets.
 12. The methodof claim 11, wherein the step of opening the plurality of fabric pocketscomprises cutting open the fabric pockets.
 13. The method of claim 11,wherein the step of opening the plurality of fabric pockets comprisescutting open the fabric pockets with a high-speed rotating blade. 14.The method of claim 11, wherein the step of gripping the fabric pocketsat the second end thereof is carried out after opening the fabricpockets at the first end thereof.
 15. The method of claim 11, whereinthe step of gripping the fabric pockets at the second end thereof iscarried out before opening the fabric pockets at the first end thereof.16. The method of claim 11, wherein the step of gripping the fabricpockets at the second end thereof comprises rotating corkscrew-likeimplements into the second end of the fabric pockets.
 17. The method ofclaim 11, wherein the step of extracting the steel coil springscomprises engaging the steel coil spring with a movable element andmoving the movable element away from the fabric pocket to pull the steelcoil spring out of the pocket.
 18. The method of claim 11, furthercomprising the step of indexing the position of the mattress beingdeconstructed to present a first row of fabric pockets and steel coilsprings for processing, and after removing the steel coil springs fromthe first row, indexing the position of the mattress again to present asubsequent row of fabric pockets and steel coil springs for processing,and continuing to process the fabric pockets and steel coil springs andindexing the position of the mattress until there are no further rows offabric pockets and steel coil springs remaining to be processed.
 19. Themethod of claim 11, wherein the mattress has already had an outer coverportion thereof removed to prepare the fabric pockets and steel coilsprings for processing.
 20. The method of claim 11, wherein the mattressis oriented substantially horizontally during processing and the step ofextracting the steel coil springs from the fabric pockets is carried outby pulling the steel coil springs downwardly, out of the fabric pockets.